An object of the present invention is to provide a pressure-heat drying method which allows a catalytic substance and the like to be deposited uniformly onto a workpiece to be dried in a dramatically short time as compared to a prior art method, and also an apparatus therefor. The present invention provides a pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method comprising: a pressure increase process for increasing a pressure in said pressure vessel to a set pressure higher than a saturated vapor pressure of said solvent at a set temperature; a temperature increase process for increasing a temperature in said pressure vessel to said set temperature under a condition where an evaporation of said solvent is suppressed with the aid of said set pressure which has been achieved through said pressure increase process; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction and deposition process for reducing said set pressure to a level lower than the saturated vapor pressure at said set temperature and thereby stimulating a rapid evaporation of said solvent so as to allow said solute to be uniformly deposited onto said workpiece.
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5. A pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method comprising:
a pressure increase process for increasing a pressure in said pressure vessel to a set pressure lower than a saturated vapor pressure for said solvent at a set temperature; a temperature increase, evaporation and deposition process for increasing a temperature in said pressure vessel to said set temperature, and thereby evaporating a certain amount of said solvent induced by a differential pressure between a saturated vapor pressure in said pressure vessel and said set pressure in said pressure vessel so as to allow said solute to be uniformly deposited onto said workpiece; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction process for reducing said set pressure.
1. A pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method comprising:
a pressure increase process for increasing a pressure in said pressure vessel to a set pressure higher than a saturated vapor pressure of said solvent at a set temperature; a temperature increase process for increasing a temperature in said pressure vessel to said set temperature under a condition where an evaporation of said solvent is suppressed with the aid of said set pressure which has been achieved through said pressure increase process; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction and deposition process for reducing said set pressure to a level lower than the saturated vapor pressure at said set temperature and thereby stimulating a rapid evaporation of said solvent so as to allow said solute to be uniformly deposited onto said workpiece.
3. A pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method comprising:
a pressure increase process for increasing a pressure in said pressure vessel to a set pressure higher than a saturated vapor pressure for said solvent at a set temperature; a temperature increase, condensation and deposition process for increasing a temperature in said pressure vessel to said set temperature and thereby evaporating a certain amount of said solvent induced by a differential pressure between a saturated vapor pressure at a temperature of a cooling section in said pressure vessel and said set pressure in said pressure vessel to form a condensation thereof in said cooling section so as to allow said solute to be uniformly deposited onto said workpiece; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction process for reducing said set pressure.
2. A pressure-heat drying method in accordance with
4. A pressure-heat drying method in accordance with
6. A pressure-heat drying method in accordance with
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The present invention relates to a pressure-heat drying method for controlling a drying process such that catalyst and the like may be uniformly deposited onto a workpiece made of porous material, such as ceramics, or metallic material, and also to an apparatus therefor.
When a workpiece to be dried, which has been coated with a solution containing catalytic substance dissolved in a solvent adhering thereto, is subjected to heat drying under atmospheric pressure, a temperature distribution within a vessel for accommodating the workpiece and applying the heat drying thereto may vary depending on locations therein and whereby the solvent adhering onto a surface of the workpiece does not evaporate uniformly, resulting in uneven deposition of the residual catalytic substance onto the surface of the workpiece having been subjected to the dry processing.
In order to cope with the above problem, there has been employed a conventional method in which a workpiece to be dried, which has been coated with a solution containing catalytic substance dissolved in solvent adhering thereto, is once subjected to an instantaneous freezing treatment to stop a movement of the catalytic substance (e.g., ions) and then the solvent is sublimated from the solution uniformly adhering to a surface of the workpiece in a solid state so as to dry the workpiece.
The above-mentioned freeze-drying method may be practiced by using, for example, a freeze-drying apparatus 50 shown in FIG. 8. To explain this method more specifically, a workpiece 60 with said solution adhering thereto is made frozen instantaneously by using liquid nitrogen or the like and brought into a vessel 51. Then, the vessel 51 is evacuated to vacuum (in the range of 10 Pa) by a vacuum pump 53 and the temperature in the vessel 51 is controlled so that it is not higher than a fusing point of the solvent (e.g., not greater than the fusing point of 0°C C. for a water used as the solvent) by a heater 52, so that the solvent adhering to the workpiece 60 to be dried may be sublimated.
However, said freeze-drying treatment is problematic in that the drying process could only take place moderately because of said treatment depending on the sublimation of the solvent adhering to the workpiece. This may lead to a problem whereby the completion of the drying process would take a considerably long period, a total of about one week. Besides, since the freeze-drying apparatus used therefor requires refrigeration facilities, vacuum evacuation facilities and so on in addition to the heating facilities, the entire unit of equipment must be large in scale and inevitably increase a cost thereof.
The present invention has been made in the light of the above-pointed problems, and an object thereof is to provide a pressure-heat drying method which allows a catalytic substance and so on to be uniformly deposited onto a workpiece to be dried in a dramatically short time period as compared to the prior art method and also a pressure-heat drying apparatus therefor.
The present invention provides a pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method characterized in comprising: a pressure increase process for increasing a pressure in said pressure vessel to a set pressure higher than a saturated vapor pressure of said solvent at a set temperature; a temperature increase process for increasing a temperature in said pressure vessel to said set temperature under a condition where an evaporation of said solvent is suppressed with the aid of said set pressure which has been achieved through said pressure increase process; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction and deposition process for reducing said set pressure to a level lower than the saturated vapor pressure at said set temperature and thereby stimulating a rapid evaporation of said solvent so as to allow said solute to be uniformly deposited onto said workpiece.
Further, an amount of evaporation of said solvent may be controlled by controlling a pressure reduction rate in said pressure reduction and deposition process.
The present invention further provides a pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method characterized in comprising: a pressure increase process for increasing a pressure in said pressure vessel to a set pressure higher than a saturated vapor pressure of said solvent at a set temperature; a temperature increase, condensation and deposition process for increasing a temperature in said pressure vessel to said set temperature and thereby evaporating a certain amount of said solvent induced by a differential pressure between a saturated vapor pressure at a temperature of a cooling section in said pressure vessel and said set pressure in said pressure vessel to form a condensation thereof in said cooling section so as to allow said solute to be uniformly deposited onto said workpiece; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction process for reducing said set pressure.
Further, an amount of said solvent to form the condensation in said cooling section may be controlled by controlling a temperature increase rate in said temperature increase, condensation and deposition process.
The present invention further provides a pressure-heat drying method for drying a workpiece to be dried in a pressure vessel, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto, said method characterized in comprising: a pressure increase process for increasing a pressure in said pressure vessel to a set pressure lower than a saturated vapor pressure of said solvent at a set temperature; a temperature increase, evaporation and deposition process for increasing a temperature in said pressure vessel to said set temperature and thereby evaporating a certain amount of said solvent induced by a differential pressure between a saturated vapor pressure in said pressure vessel and said set pressure in said pressure vessel so as to allow said solute to be uniformly deposited onto said workpiece; a pressure and temperature maintenance process for maintaining said set pressure and said set temperature in said pressure vessel at constant levels, respectively; and a pressure reduction process for reducing said set pressure.
Further, an amount of evaporation of said solvent may be controlled by controlling a temperature increase rate in said temperature increase, evaporation and deposition process.
The present invention further provides a pressure-heat drying apparatus comprising: a pressure vessel for accommodating a workpiece to be dried, said workpiece coated with a solution containing a solute dissolved in a solvent adhering thereto; a pressure regulating means for increasing a pressure in said pressure vessel to a level equal to or higher than an atmospheric pressure by introducing an air or an inert gas into said pressure vessel; a temperature regulating means for increasing a temperature in said pressure vessel to a level equal to or higher than a room temperature; a pressure and temperature maintaining means for maintaining the pressure and the temperature in said pressure vessel constantly at a set pressure and a set temperature, respectively; and a pressure reducing means for reducing the pressure in said pressure vessel to the atmospheric pressure.
Alternatively, said pressure vessel may further comprise a cooling section and a temperature in the cooling section may be controlled to be equal or lower than said set temperature. Still alternatively, said pressure vessel may further comprise a circulation means for efficiently controlling the temperature in said pressure vessel. Yet still alternatively, said pressure vessel may accommodate a plurality of said workpieces.
Preferred embodiments of a pressure-heat drying method and a pressure-heat drying apparatus according to the present invention will now be described with reference to the attached drawings.
The above-mentioned pressure vessel 11 is an approximately cylindrical shaped vessel extending in the lateral direction in FIG. 1 and the pressure vessel 11 is situated in a central location of the apparatus 1. The pressure vessel 11 is open in one end (the left hand side in FIG. 1), through which a workpiece 40 to be dried may be introduced into the pressure vessel 11 to be accommodated therein. A vessel lid 14 is provided in said one end of the pressure vessel 11, which may block the one end of the pressure vessel 11 to bring the pressure vessel 11 in a sealingly closed state. Further, both end faces of the pressure vessel 11, i.e., an inner face of the vessel lid 14 and a surface defined in the other end of the pressure vessel 11 (i.e., the right hand side inner face in
Above-mentioned pressure regulating means is constituted of a pressure gas introduction valve 13a for increasing a pressure in the pressure vessel 11 and a gas exhaust valve 13b for reducing the pressure in the pressure vessel 11. An air or an inert gas may be supplied from a compressor or a high-pressure steel cylinder into the pressure vessel 11 through this pressure gas introduction valve 13a.
Above-mentioned temperature regulating means is constituted of an external heater 12a arranged in an outer periphery of the pressure vessel 11 and an internal heater 12b disposed within the pressure vessel 11. Further, a fan 16 is also disposed in the pressure vessel 11, which functions as a circulation means for efficiently controlling the temperature in the pressure vessel 11. This fan 16 is rotationally driven by a motor 17, and this rotational driving of the fan 16 may produce an air flow 45 within the pressure vessel 11, which helps the temperature in the pressure vessel 11 to be controlled efficiently by the external heater 12a and the internal heater 12b.
Above-mentioned pressure and temperature maintaining means functions to maintain the pressure and the temperature in the pressure vessel 11 constantly at the set pressure and the set temperature, respectively, as described above, and is constituted mainly of the pressure gas introduction valve 13a and the gas exhaust valve 13b together forming said pressure regulating means, the external heater 12a and the internal heater 12b together forming said temperature regulating means, and a control means which is not shown but controls the pressure gas introduction valve 13a, the gas exhaust valve 13b, the external heater 12a and the internal heater 12b. This control means is constituted of a pressure control section for controlling the pressure gas introduction valve 13a and the gas exhaust valve 13b and a temperature control section for controlling the external heater 12a and the internal heater 12b.
The above-mentioned pressure reducing means functions to reduce the pressure in the pressure vessel 11 to the atmospheric pressure, and may be made up of said gas exhaust valve 13b.
The pressure-heat drying apparatus 1 shown in
As described above, the above-mentioned workpiece 40 to be dried is coated with the solution containing the solute dissolved in the solvent adhering thereto, and in one example, if the solute is copper sulfate prepared as a catalytic substance, an aqueous solution of copper sulfate containing the copper sulfate (the catalytic substance) dissolved in the water may be used to adhere to and thus coat therewith the workpiece 40. In one exemplary method for adhering and coating, the workpiece 40 may be dipped in the aqueous solution of copper sulfate so that the aqueous solution of copper sulfate may adhere to the workpiece 40 so as to coat the entire surface thereof. Further, as to the workpiece 40, a metallic material may be used, including, for example, ceramics in the form of a circular cylinder having a honeycomb shaped surface.
Although in the examples shown in FIG. 1 and
Then, a pressure-heat drying method for a workpiece 40 to be dried in the above-mentioned pressure-heat drying apparatus 1 of the type equipped with no cooling section, which is shown in FIG. 1 and represents one of the features of the present invention, will be described with reference to the graphs shown in
As shown in
Then, under the condition where the evaporation of the water is suppressed with the aid of the set pressure (about 1.7 MPa) which has been achieved in the pressure increase process, the temperature 21 in the pressure vessel 11 is increased from a level of about 20°C C. (the room temperature) to the set temperature of 200°C C. by activating the external heater 12a together with the internal heater 12b of the temperature regulating means (the temperature increase process). During this temperature increase process, the fan 16 is rotationally driven so as to generate an air flow 45 in the pressure vessel, which can help the temperature in the pressure vessel 11 to be efficiently regulated by the external heater 12a and the internal heater 12b. In addition, since the evaporation of the water is being suppressed under the pressure (the set pressure) higher than the saturated vapor pressure of the water at the set temperature of 200°C C., thermal energy may be supplied to the workpiece 40 but the evaporation of the water (solvent) occurs very little as the theory shows. This set temperature may be set to be equal to or higher than 100°C C. and the set temperature represented in
Then, the above-described pressure and temperature maintaining means is now activated to maintain the set pressure and the set temperature in the pressure vessel 11 at constant levels, respectively (the pressure and temperature maintenance process). It is to be noted that a time period between the goal point "c" up to the set temperature and a starting point "d" of pressure reduction (a pressure and temperature maintenance process time) is specified to be about 30 minutes.
Subsequently, the air and the water vapor in the pressure vessel are exhausted by actuating the gas exhaust valve 13b serving as the pressure reducing means so as to reduce the set pressure down to a pressure level lower than the saturated vapor pressure at the set temperature and thereby to stimulate a rapid evaporation of the water (solvent), leaving the copper sulfate (solute) deposited uniformly onto the workpiece 40 (the pressure reduction and deposition process). When the pressure in the pressure vessel 11 is reduced to be lower than the saturated vapor pressure at the set temperature of 200°C C., the evaporation of the water, which has been suppressed under the set pressure, may be triggered at a burst by using said thermal energy having been supplied to the workpiece 40 and thereby the copper sulfate is forced to be deposited uniformly onto the workpiece 40. In this regard, the amount of water evaporation per unit time period can be controlled by controlling a pressure reduction rate in this pressure reduction and deposition process.
As the pressure is lowered, also the temperature 21 in the pressure vessel 11 and associatively the saturated vapor pressure 22 tend to be lowered, but said pressure and temperature maintaining means controls the temperature 21 and the saturated vapor pressure 22 to be maintained at the set values, respectively. In the example shown in
According to the above-discussed pressure-heat drying method, since the workpiece 40, which has been coated with the aqueous solution of copper sulfate adhering to the surface thereof, can be dried within about 120 minutes, the workpiece 40 can be dried in a dramatically shorter time period as compared to the prior art method.
In the example shown in
Turning now to
In the next step, the external heater 12a and the internal heater 12b of the temperature regulating means are activated to increase the temperature 21 in the pressure vessel 11 from a level of about 20°C C. (the room temperature) to a set temperature of 200°C C. and thereby evaporate a certain amount of water induced by a differential pressure between a saturated vapor pressure in the pressure vessel 11 and the set pressure in the pressure vessel 11 so as to allow the copper sulfate to be uniformly deposited onto the workpiece 40 (the temperature increase, evaporation and deposition process). During increasing the temperature 21 in the pressure vessel 11 from the level of about 20°C C. (the room temperature) to the set temperature of 200°C C., the fan 16 is rotationally driven to generate an air flow 45 within the pressure vessel 11, which can help the temperature in the pressure vessel 11 to be regulated efficiently by the external heater 12a and the internal heater 12b. Further, the amount of water evaporation can be controlled by controlling the temperature increase rate in this temperature increase, evaporation and deposition process.
Further, since the set pressure is about 1.3 MPa, the water starts to evaporate just at a time when the saturated vapor pressure of the water exceeds the value of about 1.3 MPa. That is, when the temperature 21 in the pressure vessel 11 reaches the temperature level of about 192°C C., the water starts to evaporate and accordingly the copper sulfate begins to be deposited uniformly onto the workpiece 40. This deposition may be completed during the temperature increase process or may be performed continuously also during the pressure and temperature maintenance process, which will be described later. Also in this case, a time period from the starting point "b'" of temperature increase to the goal point "c" up to the set temperature is specified to be the temperature increase process time.
Subsequently, the above-discussed pressure and temperature maintaining means is activated to maintain the set pressure and the set temperature in the pressure vessel 11 to be constant (the pressure and temperature maintenance process). The evaporation of the water would have been almost completed in this process, and thereby the copper sulfate (the solute) could have been fully deposited over the workpiece 40. It is to be noted that a time period between the goal point "C" up to the set temperature and the starting point "d" of pressure reduction is specified to be the pressure and temperature maintenance process time.
Then, the air in the pressure vessel is exhausted through the gas exhaust valve 13b serving as the pressure reducing means to reduce the pressure 20 in the pressure vessel 11 from the level of about 1.3 MPa (the set pressure) to the level of about 0.1 MPa (the atmospheric pressure) (the pressure reduction process). It is to be noted that a time period from the starting point "d" of pressure reduction to the goal point "e" of pressure reduction is specified to be the pressure reduction process time. After the completion of this pressure reduction process, it is confirmed that the pressure within the pressure vessel 11 has been reduced down to the atmospheric pressure, and the workpiece 40 with the copper sulfate uniformly deposited thereon is cooled and then taken out of the pressure vessel 11.
Since the time period from the starting point "a" of pressure increase to the goal point "e" of pressure reduction counts as a few hours, in this method also, such a workpiece to be dried 40 that has been coated with the aqueous solution of copper sulfate adhering onto the entire surface thereof can be dried in a dramatically short time as compared to the prior art method.
An alternative pressure-heat drying method for the workpiece 40 in the above-discussed pressure-heat drying apparatus 1 of the type equipped with the cooling section, which is shown in
As shown in
Then, the external heater 12a together with the internal heater 12b of the temperature regulating means are activated to increase a temperature 21 in the pressure vessel 11 from a level of about 20°C C. (the room temperature) to the set temperature of 200°C C. thereby evaporating a certain amount of water induced by a differential pressure between a saturated vapor pressure at the temperature of the cooling section in the pressure vessel 11 and the set pressure in the pressure vessel 11 to form a condensation thereof in said cooling section so as to allow the copper sulfate to be uniformly deposited onto said workpiece to be dried (the temperature increase, condensation and deposition process). During increasing the temperature 21 in the pressure vessel 11 from the level of about 20°C C. (the room temperature) to the set temperature of 200°C C., the fan 16 is rotationally driven to generate an air flow 45 within the pressure vessel 11, which can help the temperature in the pressure vessel 11 to be regulated efficiently by the external heater 12a and the internal heater 12b. In this process, the amount of water to be condensed on this cooling section can be controlled by controlling the temperature increase rate in this temperature increase, condensation and deposition process.
When the temperature 21 in the pressure vessel 11 is increased in the above-described manner, the water therein is evaporated by a certain amount induced by a differential pressure between a saturated vapor pressure at the temperature of the cooling section in the pressure vessel 11 and the set pressure in the pressure vessel 11 and then is formed into the condensation in the cooling section with the aid of the low temperature of the cooling section since the temperature 23 of the cooling section is maintained to be constant at a lower level (of about 50°C C. in the example shown in FIG. 7). This water of condensation may be drained through a drain valve 65 as needed. By repeating this cycle of evaporation, condensation and drainage of the water, the copper sulfate can be progressively deposited uniformly over the workpiece 40. This deposition may be completed during the temperature increase, condensation and deposition process or may be performed continuously also during the pressure and temperature maintenance process, as will be described later. In this case, a time period between the starting point "b'" of temperature increase and the goal point "c" up to the set temperature is specified to be the temperature increase, condensation and deposition process time.
Subsequently, said pressure and temperature maintaining means is activated to maintain the set pressure and the set temperature in the pressure vessel 11 to be constant (the pressure and temperature maintenance process). The evaporation of the water would have been completed during this process, and thereby the copper sulfate (the solute) could have been fully and uniformly deposited over the workpiece 40. It is to be noted that a time period between the goal point "c" up to the set temperature and the starting point "d" of pressure reduction is specified to be the pressure and temperature maintenance process time.
Subsequently, the air in the pressure vessel 11 is exhausted through the gas exhaust valve 13b serving as the pressure reducing means so as to reduce the pressure 20 in the pressure vessel 11 from the level of about 1.7 MPa (the set pressure) to the pressure level of about 0.1 MPa (the atmospheric pressure) (the pressure reduction process). It is to be noted that a time period from the starting point "d" of pressure reduction to the goal point "e" of pressure reduction is specified to be the pressure reduction process time. After the completion of this pressure reduction process, it is confirmed that the pressure in the pressure vessel 11 has been reduced to atmospheric pressure, and the workpiece 40 with the copper sulfate deposited uniformly thereon is cooled and then taken out of the pressure vessel 11.
Since the time period between the starting point "a" of pressure increase and the goal point "e" of pressure reduction counts as a few hours, in this method also, such a workpiece to be dried 40 that has been coated with the aqueous solution of copper sulfate adhering onto an entire surface thereof can be dried in a dramatically short time as compared to that of the prior art.
According to the present invention, since the pressure process has been employed, the catalytic material and so on can be deposited uniformly onto a workpiece to be dried yet in a dramatically short time as compared to the prior art method.
The entire disclosure of Japanese Patent Application No.2002-025164 filed on Feb. 1, 2002, including specification, claims, drawings, and summary is incorporated herein by reference in their entirety.
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